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Stonemasonry or stonecraft is the creation of buildings, structures, and sculpture using stone as the primary material. Stonemasonry is the craft of shaping and arranging stones, often together with mortar and even the ancient lime mortar, to wall or cover formed structures.
The basic tools, methods and skills of the banker mason have existed as a trade for thousands of years. It is one of the oldest activities and professions in human history. Many of the long-lasting, ancient shelters, temples, monuments, artifacts, fortifications, roads, bridges, and entire cities were built of stone. Famous works of stonemasonry include Göbekli Tepe, the Egyptian pyramids, the Taj Mahal, Cusco's Incan Wall, Taqwesan, Easter Island's statues, Angkor Wat, Borobudur, Tihuanaco, Tenochtitlan, Persepolis, the Parthenon, Stonehenge, the Great Wall of China, the Mesoamerican pyramids, Chartres Cathedral, and the Stari Most.
While stone was important traditionally, it fell out of use in the modern era, in favor of brick and steel-reinforced concrete. This is despite the advantages of stone over concrete. Those advantages include:
Modern stonemasonry is in the process of reinventing itself for automation, modern load-bearing stone construction, innovative reinforcement techniques, and integration with other sustainable materials, like engineered wood.
Stone has been used in construction for thousands of years, in many contexts. Listed below are six types of classical stonemasonry techniques, some of which still see widespread use.
In the modern era, stone has been largely relegated as a cosmetic element of buildings, often used as decorative cladding on steel-reinforced concrete. This is despite its wide historical use in large compressive structures: 50-m bridges and colosseums in Roman times, ~65-m tall cathedrals since the middle ages, and 12-story apartment buildings built in the 1690s. [5]
Massive precut stone is also known as "prefabricated", or "pre-sized" stone is a modern method of building with load-bearing stone. [22] Precut stone is a DFMA construction method that uses large machine-cut stone blocks with precisely defined dimensions to rapidly assemble buildings in which stone is used as a major or the primary load-bearing material.
Massive precut stone construction was originally developed by Fernand Pouillon in postwar period who referred to the method as "pierre de taille" or "pré-taille" stone. It became possible through innovations by Pouillon and Paul Marcerou, a masonry engineer at a quarry in Fontvieille, to adapt high-precision saws from the timber industry to quarrying and stone sawing. [23]
The key technique of massive precut (MP) stone is to cut stone ashlars to precise dimensions that match the architect's plan such that the stones can be dropped into place by crane for rapid construction. [22] The blocks may be numbered so that the masons can follow the plan procedurally. The use of massive blocks reduces costs by minimizing sawing and fixer-masonry costs. The use of a crane reduces labor, accelerates construction, and allows the masons to precisely and quickly position the blocks.
MP stone is defined by four design attributes.
MP stone construction has advantages over conventional masonry and concrete construction.
Fernand Pouillon pioneered the use of massive precut stone in modern architecture. During the post-war period, his innovative approach to stone construction led to the development of numerous noteworthy projects, with a particular focus on housing. Throughout his long career, Pouillon played a crucial role in the development and popularization of massive precut stone construction techniques. His pioneering work laid the foundation for subsequent architects to build upon and innovate, leading to the resurgence and expansion of this construction method in the 2020s, with the rise of interest in low-carbon durable construction.
Post-tensioned stone is a high-performance composite construction material: stone held in compression with tension elements. The tension elements can be connected to the outside of the stone, but more typically uses tendons threaded internally through a duct formed from aligned drilled holes.
Post-tensioned stone ("PT stone") could consist of a single piece, but drill limitations and other considerations mean it is typically an assembly of multiple components with mortar between pieces. PT stone has been used in both vertical columns (posts), and in horizontal beams (lintels). It has also been used in more unusual engineering applications: arch stabilization, flexible foot bridges, and cantilevered sculptures.
Tensioned stone has a close affiliation with massive precut stone as two central techniques of modern stonemasonry.
"Post-tensioned stone increases the failure load of stone in bending, but also the stiffness of a structure by reducing joint cracking. This method of construction is widely used for concrete structures, but the advantages of using similar techniques with stone are only just being realised". [28]
Stone has great compressive strength, so is ideal in compressive structures like stone arches. [29] However, it has relatively weak flexural strength (compared to steel or wood), so in isolation cannot be safely used in wide spans under tension. [29]
For concrete, this problem has been long solved: in addition to conventional tensile reinforcement, engineers developed prestressed concrete methods starting around 1888. Such tension-reinforced concrete applications combine compressive strength with pre-stressed tensile compression for combined strength much greater than either of the individual components, and have been in wide use for decades. As for concrete, post-tensioning maintains stone in compression, thereby increasing its strength.
Post-tensioning is achieved steel tendons either threaded through ducts within the stone elements or along their surface. Once the stone components are in place, the tendons are tensioned using hydraulic jacks, and the force is transferred to the stone through anchorages located at the ends of the tendons. The tensioning process imparts a compressive force to the stone, which improves its capacity to resist tensile stresses that could otherwise cause cracking or failure.
Stone is 'natural precast concrete' so only needs to be cut (and strength tested) and post-tensioned prior to use in construction. Compared to concrete and steel, post-tensioned stone production has dramatically lower energy costs, with concomitant lower carbon emissions. [30]
Stonemasonry is one of the earliest trades in civilization's history. During the time of the Neolithic Revolution and domestication of non-human animals, people learned how to use fire to create quicklime, plasters, and mortars. They used these to fashion homes for themselves with mud, straw or stone, and masonry was born.
The Ancients heavily relied on the stonemason to build the most impressive and long-lasting monuments to their civilizations. The Egyptians built their pyramids, the civilizations of Central America had their step pyramids, the Persians their palaces, the Greeks their temples, and the Romans their public works and wonders (See Roman Architecture). People of the Indus Valley Civilization, such as at Dholavira made entire cities characterized by stone architecture. Among the famous ancient stonemasons is Sophroniscus, the father of Socrates, who was a stone-cutter.
Castle building was an entire industry for the medieval stonemasons. When the Western Roman Empire fell, building in dressed stone decreased in much of Western Europe, and there was a resulting increase in timber-based construction. Stonework experienced a resurgence in the 9th and 10th centuries in Europe, and by the 12th-century religious fervour resulted in the construction of thousands of impressive churches and cathedrals in stone across Western Europe.
Medieval stonemasons' skills were in high demand, and members of the guild, gave rise to three classes of stonemasons: apprentices, journeymen, and master masons. Apprentices were indentured to their masters as the price for their training, journeymen were qualified craftsmen who were paid by the day, and master masons were considered freemen who could travel as they wished to work on the projects of the patrons and could operate as self-employed craftsmen and train apprentices. During the Renaissance, the stonemason's guild admitted members who were not stonemasons, and eventually evolved into the Society of Freemasonry; fraternal groups which observe the traditional culture of stonemasons but are not typically involved in modern construction projects.
A medieval stonemason would often carve a personal symbol onto their block to differentiate their work from that of other stonemasons. This also provided a simple ‘quality assurance’ system.
The Renaissance saw stonemasonry return to the prominence and sophistication of the Classical age. The rise of the humanist philosophy gave people the ambition to create marvelous works of art. The centre stage for the Renaissance would prove to be Italy, where Italian city-states such as Florence erected great structures, including the Florence Cathedral, the Fountain of Neptune, and the Laurentian Library, which was planned and built by Michelangelo Buonarroti, a famous sculptor of the Renaissance.
When Europeans settled the Americas, they brought the stonemasonry techniques of their respective homelands with them. Settlers used what materials were available, and in some areas, stone was the material of choice. In the first waves, building mimicked that of Europe, to eventually be replaced by unique architecture later on.
In the 20th century, stonemasonry saw its most radical changes in the way the work is accomplished. Prior to the first half of the century, most heavy work was executed by draft animals or human muscle power. With the arrival of the internal combustion engine, many of these hard aspects of the trade have been made simpler and easier. Cranes and forklifts have made moving and laying heavy stones relatively easy for the stonemasons. Motor powered mortar mixers have saved much in time and energy as well. Compressed-air powered tools have made working of stone less time-intensive. Petrol and electric-powered abrasive saws can cut through stone much faster and with more precision than chiseling alone. Cemented carbide-tipped chisels can stand up to much more abuse than the steel and iron chisels made by blacksmiths of old.
Stonemasons use a wide variety of tools to handle and shape stone blocks (ashlar) and slabs into finished articles. The basic tools for shaping the stone are a mallet, chisels, and a metal straight edge. With these one can make a flat surface – the basis of all stonemasonry.
Chisels come in a variety of sizes and shapes, dependent upon the function for which they are being used and have many different names depending on locality. There are different chisels for different materials and sizes of material being worked, for removing large amounts of material and for putting a fine finish on the stone. A drove chisel is used for smoothing off roughly finished stones.
Mixing mortar is normally done today with mortar mixers which usually use a rotating drum or rotating paddles to mix the mortar.
The masonry trowel is used for the application of the mortar between and around the stones as they are set into place. Filling in the gaps (joints) with mortar is referred to as pointing. Pointing in smaller joints can be accomplished using tuck pointers, pointing trowels, and margin trowels, among other tools.
A mason's hammer has a long thin head and is called a Punch Hammer. It would be used with a chisel or splitter for a variety of purposes
A walling hammer (catchy hammer) can be used in place of a hammer and chisel or pincher to produce rubble or pinnings or snecks.
Stonemasons use a lewis together with a crane or block and tackle to hoist building stones into place.
Today power tools such as compressed-air chisels, abrasive spinners, and angle grinders are much used: these save time and money, but are hazardous and require just as much skill as the hand tools that they augment. But many of the basic tools of stonemasonry have remained virtually the same throughout vast amounts of time, even thousands of years, for instance when comparing chisels that can be bought today with chisels found at the pyramids of Giza the common sizes and shapes are virtually unchanged.
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Traditionally medieval stonemasons served a seven-year apprenticeship. A similar system still operates today.
A modern apprenticeship lasts three years. This combines on-site learning through personal experience, the experience of the tradesmen, and college work where apprentices are given an overall experience of the building, hewing and theory work involved in masonry. In some areas, colleges offer courses which teach not only the manual skills but also related fields such as drafting and blueprint reading or construction conservation. Electronic Stonemasonry training resources enhance traditional delivery techniques. Hands-on workshops are a good way to learn about stonemasonry also. Those wishing to become stonemasons should have little problem working at heights, possess reasonable hand-eye coordination, be moderately physically fit, and have basic mathematical ability. Most of these things can be developed while learning.
The modern stonemason undergoes comprehensive training, both in the classroom and in the working environment. Hands-on skill is complemented by an intimate knowledge of each stone type, its application, and best uses, and how to work and fix each stone in place. The mason may be skilled and competent to carry out one or all of the various branches of stonemasonry. In some areas, the trend is towards specialization, in other areas towards adaptability.
Today's stonemasons undergo training that is quite comprehensive and is done both in the work environment and in the classroom. It isn't enough to have hands-on skills only. One must also have knowledge of the types of stones as well as its best uses and how to work it as well as how to fix it in place. [32]
Stonemasons use all types of natural stone: igneous, metamorphic and sedimentary; while some also use artificial stone as well.
Many of the world's most famous buildings have been built of sedimentary stone, from Durham Cathedral to St Peter's in Rome. There are two main types of sedimentary stone used in masonry work, limestones and sandstones. Examples of limestones include Bath and Portland stone. Yorkstone and Sydney sandstone are the most commonly used sandstone.
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A brick is a type of construction material used to build walls, pavements and other elements in masonry construction. Properly, the term brick denotes a unit primarily composed of clay, but is now also used informally to denote units made of other materials or other chemically cured construction blocks. Bricks can be joined using mortar, adhesives or by interlocking. Bricks are usually produced at brickworks in numerous classes, types, materials, and sizes which vary with region, and are produced in bulk quantities.
Masonry is the craft of building a structure with brick, stone, or similar material, including mortar plastering which are often laid in, bound, and pasted together by mortar. The term masonry can also refer to the building units themselves.
An arch bridge is a bridge with abutments at each end shaped as a curved arch. Arch bridges work by transferring the weight of the bridge and its loads partially into a horizontal thrust restrained by the abutments at either side, and partially into a vertical load on the arch supports. A viaduct may be made from a series of arches, although other more economical structures are typically used today.
A bricklayer, which is related to but different from a mason, is a craftsperson and tradesperson who lays bricks to construct brickwork. The terms also refer to personnel who use blocks to construct blockwork walls and other forms of masonry. In British and Australian English, a bricklayer is colloquially known as a "brickie". A stone mason is one who lays any combination of stones, cinder blocks, and bricks in construction of building walls and other works. Bricklaying is a part of masonry.
Stone carving is an activity where pieces of rough natural stone are shaped by the controlled removal of stone. Owing to the permanence of the material, stone work has survived which was created during our prehistory or past time.
A concrete block, also known as a cinder block in North American English, breeze block in British English, concrete masonry unit (CMU), or by various other terms, is a standard-size rectangular block used in building construction. The use of blockwork allows structures to be built in the traditional masonry style with layers of staggered blocks.
This page is a list of construction topics.
Ashlar is a cut and dressed stone, worked using a chisel to achieve a specific form, typically rectangular in shape. The term can also refer to a structure built from such stones.
Cyclopean masonry is a type of stonework found in Mycenaean architecture, built with massive limestone boulders, roughly fitted together with minimal clearance between adjacent stones and with clay mortar or no use of mortar. The boulders typically seem unworked, but some may have been worked roughly with a hammer and the gaps between boulders filled in with smaller chunks of limestone. It is similar to Indian masonry such as the Cyclopean Wall of Rajgir.
Repointing is the process of renewing the pointing, which is the external part of mortar joints, in masonry construction. Over time, weathering and decay cause voids in the joints between masonry units, usually in bricks, allowing the undesirable entrance of water. Water entering through these voids can cause significant damage through frost weathering and from salt dissolution and deposition. Repointing is also called pointing, or pointing up, although these terms more properly refer to the finishing step in new construction.
A stonemason's hammer, also known as a brick hammer, has one flat traditional face and a short or long chisel-shaped blade. It can thus be used to chip off edges or small pieces of stone, cut brick or a concrete masonry unit, without using a separate chisel. The chisel blade can also be used to rapidly cut bricks or cinder blocks. This type of hammer is also used by geologists when collecting rock and mineral samples and is one of several types of geologist's hammer.
Inca architecture is the most significant pre-Columbian architecture in South America. The Incas inherited an architectural legacy from Tiwanaku, founded in the 2nd century B.C.E. in present-day Bolivia. A core characteristic of the architectural style was to use the topography and existing materials of the land as part of the design. The capital of the Inca empire, Cuzco, still contains many fine examples of Inca architecture, although many walls of Inca masonry have been incorporated into Spanish Colonial structures. The famous royal estate of Machu Picchu is a surviving example of Inca architecture. Other significant sites include Sacsayhuamán and Ollantaytambo. The Incas also developed an extensive road system spanning most of the western length of the continent and placed their distinctive architecture along the way, thereby visually asserting their imperial rule along the frontier.
The Cataract Dam is a heritage-listed dam in Cataract, New South Wales, Australia, provides water to the Macarthur and Illawarra regions, the Wollondilly Shire, and metropolitan Sydney. It is one of four dams and weirs in the catchment of the Upper Nepean Scheme. Completed in 1907 under the supervision of Ernest Macartney de Burgh, the dam is currently owned by Water NSW, an agency of the Government of New South Wales. The dam was listed on the NSW State Heritage Register on 18 November 1999.
Stone veneer is a thin layer of any stone used as decorative facing material that is not meant to be load bearing. Stone cladding is a stone veneer, or simulated stone, applied to a building or other structure made of a material other than stone. Stone cladding is sometimes applied to concrete and steel buildings as part of their original architectural design.
Rubble masonry or rubble stone is rough, uneven building stone not laid in regular courses. It may fill the core of a wall which is faced with unit masonry such as brick or ashlar. Some medieval cathedral walls have outer shells of ashlar with an inner backfill of mortarless rubble and dirt.
The history of construction traces the changes in building tools, methods, techniques and systems used in the field of construction. It explains the evolution of how humans created shelter and other structures that comprises the entire built environment. It covers several fields including structural engineering, civil engineering, city growth and population growth, which are relatives to branches of technology, science, history, and architecture. The fields allow both modern and ancient construction to be analyzed, as well as the structures, building materials, and tools used.
Thomas Frazer was an American mason known for his work in Beaver, Utah. Born in Lortny, Scotland, he created many works that are listed on the U.S. National Register of Historic Places.
This glossary of structural engineering terms pertains specifically to structural engineering and its sub-disciplines. Please see glossary of engineering for a broad overview of the major concepts of engineering.
Tensioned stone is a high-performance composite construction material: stone held in compression with tension elements. The tension elements can be connected to the outside of the stone, but more typically tendons are threaded internally through a drilled duct.
Massive-precut stone is a modern stonemasonry method of building with load-bearing stone. Precut stone is a DFMA construction method that uses large machine-cut dimension stone blocks with precisely defined dimensions to rapidly assemble buildings in which stone is used as a major or the sole load-bearing material.